Hygiene and safety aspects The regulations relating to food production are continually being tightened with the aim of improving the safety of food products and he safety of people working in food factories If you work in a food factory you must be acquainted with the potential vent becoming contaminated with noxious substances. You must make sure that your actions do not put yourself or your colleagues at risk of injury 3. 1 Safety of food products Biscuits will be unfit or unpleasant to eat if they are contaminated in the course of their manufacture and packaging. Contaminated means that unwanted material becomes included in or on them. Some forms of contamination may be positively dangerous to the health of those who eat the biscuits It is therefore important that the problem of contamination is onsidered because it is the basis of food hygiene which is the responsibility of all who work with food It is not possible to list all the possible hazards to hygiene that may be encountered in a biscuit factory bu should help to make you aware of the likely problem areas 3.2 Sources of contamination 3.2.1 People Contamination may come from people via the microorganisms their hands. Hairs, buttons and pieces of jewellery may fall from their bodies and clothes and articles may fall from pockets. The most important requirement for all those who handle, or are likely to handle food, is to observe basic rules of personal hygiene
3 Hygiene and safety aspects The regulations relating to food production are continually being tightened with the aim of improving the safety of food products and the safety of people working in food factories. If you work in a food factory you must be acquainted with the potential dangers and constantly endeavour to prevent the food becoming contaminated with noxious substances. You must also make sure that your actions do not put yourself or your colleagues at risk of injury. 3.1 Safety of food products Biscuits will be unfit or unpleasant to eat if they are contaminated in the course of their manufacture and packaging. Contaminated means that unwanted material becomes included in or on them. Some forms of contamination may be positively dangerous to the health of those who eat the biscuits. It is therefore important that the problem of contamination is considered because it is the basis of food hygiene which is the responsibility of all who work with food. It is not possible to list all the possible hazards to hygiene that may be encountered in a biscuit factory but the following section should help to make you aware of the likely problem areas. 3.2 Sources of contamination 3.2.1 People Contamination may come from people via the microorganisms on their hands. Hairs, buttons and pieces of jewellery may fall from their bodies and clothes and articles may fall from pockets. The most important requirement for all those who handle, or are likely to handle food, is to observe basic rules of personal hygiene. 8
Hygiene and safety aspects 9 Disease is quickly spread if food handlers are negligent about hand washing following visits to toilets. It is very unpleasant to have food contaminated with grease or other dirt from unwashed At all food premises good, clean washing facilities must be provided with continuous supplies of hot and cold scented soap and disposable towels. Cold water with no soap and communal towels are not adequate. Hand washing sinks and facilities must be separate from those used to wash equipment. All food handlers must ensure that their hands are washed and clean before handling food and it is particularly important that their hands are washed after each visit to Employers must provide clean overalls and hair coverings for all personnel. These should be worn only in the food factory. NO ose money, pins, jewellery (other than plain wedding rings), watches, radios, books, news- papers and smoking tackle should be allowed into the production areas. Hair brushing or combing necessitating removal of head gear should be forbidden in production areas. In this way the possibility of contamination by loose articles is signifi cantly reduced Smoking involves the hands becoming contaminated with saliva and the by-products -matches, ash and cigarette ends, are particularly repulsive. No smoking should ever be allowed in the production areas. Operators who have cuts, abrasions or skin infections, particularly on the hands or arms, should be especially careful. Bandages or dressings should be of good quality and be, at least partly, brightly coloured and easily detectable should they be lost. In those premises where metal detectors are available for product scanning, it is additionally useful for the bandages to contain metal strips that will be found automatically should a bandage be lost in the product. Food handlers suffering from intestinal complaints such diarrhoea or other contagious diseases should be required ay from production areas until they recover. frequently necessary for operators to carry certain small with them in the course of their duties. Articles such as pens, pencils, gauges and various tools should not be
Hygiene and safety aspects 9 Disease is quickly spread if food handlers are negligent about hand washing following visits to toilets. It is very unpleasant to have food contaminated with grease or other dirt from unwashed hands. At all food premises good, clean washing facilities must be provided with continuous supplies of hot and cold water, nonscented soap and disposable towels. Cold water with no soap and communal towels are not adequate. Hand washing sinks and facilities must be separate from those used to wash equipment. All food handlers must ensure that their hands are washed and clean before handling food and it is particularly important that their hands are washed after each visit to the toilet. Employers must provide clean overalls and hair coverings for all personnel. These should be worn only in the food factory. No personal food, drink containers, loose money, pins, jewellery (other than plain wedding rings), watches, radios, books, newspapers and smoking tackle should be allowed into the production areas. Hair brushing or combing necessitating removal of head gear should be forbidden in production areas. In this way the possibility of contamination by loose articles is significantly reduced. Smoking involves the hands becoming contaminated with saliva and the by-products - matches, ash and cigarette ends, are particularly repulsive. No smoking should ever be allowed in the production areas. Operators who have cuts, abrasions or skin infections, particularly on the hands or arms, should be especially careful. Bandages or dressings should be of good quality and be, at least partly, brightly coloured and easily detectable should they be lost. In those premises where metal detectors are available for product scanning, it is additionally useful for the bandages to contain metal strips that will be found automatically should a bandage be lost in the product. Food handlers suffering from intestinal complaints such as diarrhoea or other contagious diseases should be required to keep away from production areas until they recover. It is frequently necessary for operators to carry certain small articles with them in the course of their duties. Articles such as pens, pencils, gauges and various tools should not be
carried in top pockets in case, while bending over, they should fall into the product or machines. Overalls provided with no top Where gloves are needed either of fabric type (as for chocolate handling) or waterproof, they require regular washing and drying both inside and out. Gloves should not be used by more than one person and they should be replaced when 3.2.2 Emptying containers When bags or boxes are opened and emptied there is a great potential for contamination Pieces of string or paper removed in the opening process must be placed in rubbish bins and not on the floor. Before inverting a bag, box or other type of container, ensure that it has not collected floor or surface dirt that could fall into an Dispose of the empty container in a responsible way so that pillage or dust is avoided as much as possible and it is not a danger to other workers 3.2.3 Small items of equipment In most biscuit factories it is necessary to use bowls, beakers or trays to carry and weigh ingredients or dough. These should be made of metal or plastic because glass is particularly dangerous, making splinters or small fragments if broken. Glass containers must never be taken into production areas. Where ingredients are delivered in glass containers they should be dispensed into non-breakable containers in specially esignated rooms away from the production areas Colour coding of containers is better than labels which may fall off. Elastic bands provide a particular hazard due to their tendency to fly off in unexpected directions and become lost All utensils should be stored, full or empty, on special clean stillage so that they are off the floor. This is to ensure that when inverted no floor dirt can fall from them on to product or into a mixer. After use all containers should be washed in hot water, with detergent as necessary, and left inverted to dry
10 Biscuit, cookie and cracker manufacturing manuals carried in top pockets in case, while bending over, they should fall into the product or machines. Overalls provided with no top pockets remove this possibility! Where gloves are needed either of fabric type (as for chocolate handling) or waterproof, they require regular washing and drying both inside and out. Gloves should not be used by more than one person and they should be replaced when damaged. 3.2.2 Emptying containers When bags or boxes are opened and emptied there is a great potential for contamination. Pieces of string or paper removed in the opening process must be placed in rubbish bins and not on the floor. Before inverting a bag, box or other type of container, ensure that it has not collected floor or surface dirt that could fall into an unwanted place. Dispose of the empty container in a responsible way so that spillage or dust is avoided as much as possible and it is not a danger to other workers. 3.2.3 Small items of equipment In most biscuit factories it is necessary to use bowls, beakers or trays to carry and weigh ingredients or dough. These should be made of metal or plastic because glass is particularly dangerous, making splinters or small fragments if broken. Glass containers must never be taken into production areas. Where ingredients are delivered in glass containers they should be dispensed into non-breakable containers in specially designated rooms away from the production areas. Colour coding of containers is better than labels which may fall off. Elastic bands provide a particular hazard due to their tendency to fly off in unexpected directions and become lost. All utensils should be stored, full or empty, on special clean stillage so that they are off the floor. This is to ensure that when inverted no floor dirt can fall from them on to product or into a mixer. After use all containers should be washed in hot water, with detergent as necessary, and left inverted to dry
Hygiene and safety aspects 11 Cleaning equipment such as cloths, brushes, mops and scrapers should be stored and dried after use on specially provided racks ils, off the fle Detergents used for cleaning equipment must be of approved types and stocks must be stored separately away from ingredients or dough containers ffice equipment such as elastic bands, paper clips and particularly pins should be forbidden in the factory environ 3.2.4 Plant machinery At the end of each production run all machines should be cleaned immediately so that buildup of dough or other materials does not become hard, or mouldy and an attraction for insects As a basic principle, all food machinery should be mounted off the floor so that the floor can be thoroughly swept or washed at regular intervals Covers for the moving parts of machinery should be properly fixed at all times and kept in good repair. All surfaces should be wiped down regularly and washed with warm water and detergent if necessary. Fabric conveyors should be checked regularly to watch for frayed edges or seams. If necessary these should be trimmed with a sharp knife or the conveyor replaced If a machine is not to be used for some time it should be covered with a dust sheet Drip trays and other catch containers must be emptied and cleaned regularly, but certainly at the end of each production run. Particular care should be taken that mineral lubricating oils and greases do not contaminate food. Leaking motors, gearboxes or bearings should be reported without delay for engineering Where it is necessary to climb up to high parts of machines or here walkways or ladders are needed to get over machines special walkways with adequate guarding should be provided to prevent floor dirt, carried on footwear, dropping on to dough, products or food surfaces No string should ever be used to attach wires or other articles in production areas and fibrous or loose insulation materials should e covered and fixed securely to prevent disintegrate
Hygiene and safety aspect8 11 Cleaning equipment such as cloths, brushes, mops and scrapers should be stored and dried after use on specially provided racks, hooks or rails, off the floor. Detergents used for cleaning equipment must be of approved types and stocks must be stored separately away from ingredients or dough containers. Office equipment such as elastic bands, paper clips and particularly pins should be forbidden in the factory environment. 3.2.4 Plant machinery . . . . . . . . . At the end of each production run all machines should be cleaned immediately so that buildup of dough or other materials does not become hard, or mouldy and an attraction for insects. As a basic principle, all food machinery should be mounted off the floor so that the floor can be thoroughly swept or washed at regular intervals. Covers for the moving parts of machinery should be properly fixed at all times and kept in good repair. All surfaces should be wiped down regularly and washed with warm water and detergent if necessary. Fabric conveyors should be checked regularly to watch for frayed edges or seams. If necessary these should be trimmed with a sharp knife or the conveyor replaced. If a machine is not to be used for some time it should be covered with a dust sheet. Drip trays and other catch containers must be emptied and cleaned regularly, but certainly at the end of each production run. Particular care should be taken that mineral lubricating oils and greases do not contaminate food. Leaking motors, gearboxes or bearings should be reported without delay for engineering maintenance. Where it is necessary to climb up to high parts of machines or where walkways or ladders are needed to get over machines, special walkways with adequate guarding should be provided to prevent floor dirt, carried on footwear, dropping on to dough, products or food surfaces. No string should ever be used to attach wires or other articles in production areas and fibrous or loose insulation materials should be covered and fixed securely to prevent disintegration
12 Biscuit, cookie and cracker manufacturing manuals Nowhere in production areas should wood be used. This is easily splintered and pieces find their way into ingredients or dough completely removed from the production area and stored preferably in a reasonably clean condition) in a store remote from the factory. In many factories the machinery graveyard is an ideal home for marauding rats, mice and insects. It is ideal from their point of view because it is dry and undisturbed. Food can be taken there and breeding take place in relative comfort! The convenience of such a home should be denied within the 3. 2.5 Buildings and general factory areas A major source of contamination is from insects, animals and birds Also dirt or loose particles falling from overhead areas offer potential hazards Flying insects and birds must be excluded from the factory by sing screens over ventilation fans and windows which open Open doorways should have plastic strip or air curtains to prevent entry of insects and birds Doors to the outside should fit closely to the floor so that animals cannot enter at night or other times Rodent control systems should be regularly maintained and any bait must be placed only in specially designed and sited containers hich are clearly marked. Damaged bait containers should be disposed of immediately and safely. Trunking for wiring and other services should be well sealed to reduce the chance of dust accumulation followed by insect infestation High ledges and roof supports where dust can collect should be of sloping construction and be cleaned regularly. Good lighting should be maintained in all production areas and plastic screening, where appropriate, should be used to prevent glass falling on to the product if light bulbs or tubes are broken It is a requirement that all food workers are aware of these potentials for contamination and that they report to man- agement, without delay, any aspects that do not seem
12 Biscuit, cookie and cracker manufacturing manuals Nowhere in production areas should wood be used. This is easily splintered and pieces find their way into ingredients or dough. As machinery is replaced or becomes obsolete it should be completely removed from the production area and stored (preferably in a reasonably clean condition) in a store remote from the factory. In many factories the machinery graveyard is an ideal home for marauding rats, mice and insects. It is ideal from their point of view because it is dry and undisturbed. Food can be taken there and breeding take place in relative comfort! The convenience of such a home should be denied within the production environment. 3.2.5 A major source of contamination is from insects, animals and birds. Also dirt or loose particles falling from overhead areas offer potential hazards. Buildings and general factory areas Flying insects and birds must be excluded from the factory by using screens over ventilation fans and windows which open. Open doorways should have plastic strip or air curtains to prevent entry of insects and birds. Doors to the outside should fit closely to the floor so that animals cannot enter at night or other times. Rodent control systems should be regularly maintained and any bait must be placed only in specially designed and sited containers which are clearly marked. Damaged bait containers should be disposed of immediately and safely. Trunking for wiring and other services should be well sealed to reduce the chance of dust accumulation followed by insect infestation. High ledges and roof supports where dust can collect should be of sloping construction and be cleaned regularly. Good lighting should be maintained in all production areas and plastic screening, where appropriate, should be used to prevent glass falling on to the product if light bulbs or tubes are broken. It is a requirement - that all food workers are aware of these potentials for contamination and that they report to management¶ without delay, any aspects that do not seem satisfactory
Hygiene and safety aspects 13 3.3 Safety of people Your employer is required to ensure that the areas in which employees work and the machinery they use is safe. However, if employees are negligent in reporting faults or in cleaning operations etc. it is possible that an otherwise safe situation can become unsafe You should therefore be aware of where unsafe situations may arise hich could affect you or your colleagues 3.3.1 Floors Dirty floors which have become wet or greasy are slippery. Clean up 3.3.2 Machine guard Moving parts, especially those where a nip is involved, must be guarded to prevent hands or clothing becoming trapped. It is articularly dangerous to run a machine with these guards removed Experience shows that accidents involving machines occur more often to'experiencedoperatives. They become overconfident and try to overcome problems by running machines with guards 3.3.3 Electrical connections Most machinery is driven and controlled by electricity. For safety and other reasons the connections and other electronic components are housed in cabinets or under guards. The danger of electricity cannot be seen, so it is very dangerous to remove guards. Faults in electrical apparatus must be reported to management or responsible engineers
Hygiene and safety aspects 13 3.3 Safety of people Your employer is required to ensure that the areas in which employees work and the machinery they use is safe. However, if employees are negligent in reporting faults or in cleaning operations etc. it is possible that an otherwise safe situation can become unsafe. You should therefore be aware of where unsafe situations may arise which could affect you or your colleagues. 3.3.1 Floors Dirty floors which have become wet or greasy are slippery. Clean up as necessary. 3.3.2 Machine guards Moving parts, especially those where a nip is involved, must be guarded to prevent hands or clothing becoming trapped. It is particularly dangerous to run a machine with these guards removed. Experience shows that accidents involving machines occur more often to ‘experienced’ operatives. They become overconfident and try to overcome problems by running machines with guards removed. 3.3.3 Electrical connections Most machinery is driven and controlled by electricity. For safety and other reasons the connections and other electronic components are housed in cabinets or under guards. The danger of electricity cannot be seen, so it is very dangerous to remove guards. Faults in electrical apparatus must be reported to management or responsible engineers
3.3.4 Strain injuries Back strain is a common injury experienced by factory workers. It is unpleasant for the person who receives it and a potential cost to the employer due to the need for sickness leave. Back strain derives from physical effort done incorrectly or carelessly. Think when moving and lifting bags, boxes or pieces of machinery. If they are too heavy get help. If the floor is slippery take extra care. Do not try to lift something too high without help Do not expect a colleague to help you if he or she is not clear what is expected or is not strong enough to do it. 3.3.5 Dust Dirt is defined as material in the wrong place! Dust soon becomes dirt. It is unpleasant, may be dangerous to breath and may accumulate and fall into containers bearing food or ingredients Make sure that your actions cause as little dust as possible and clean up after you 3.3.6 Building maintenance hen repairs and decoration are being done it is essential that nearby production equipment is covered with sheets so that particles of metal, glass, masonry and paint do not fall into places where they could later be included with dough or product. a magnet provides a useful means of collecting most metal particles
14 Biscuit, cookie and cracker manufacturing manuals 3.3.4 Strain injuries Back strain is a common injury experienced by factory workers. It is unpleasant for the person who receives it and a potential cost to the employer due to the need for sickness leave. Back strain derives from physical effort done incorrectly or carelessly. Think when moving and lifting bags, boxes or pieces of machinery. If they are too heavy get help. If the floor is slippery take extra care. Do not try to lift something too high without help. Do not expect a colleague to help you if he or she is not clear what is expected or is not strong enough to do it. 3.3.5 Dust Dirt is defined as material in the wrong place! Dust soon becomes dirt. It is unpleasant, may be dangerous to breath and may accumulate and fall into containers bearing food or ingredients. Make sure that your actions cause as little dust as possible and clean up after you. 3.3.6 Building maintenance When repairs and decoration are being done it is essential that nearby production equipment is covered with sheets so that particles of metal, glass, masonry and paint do not fall into places where they could later be included with dough or product. A magnet provides a useful means of collecting most metal particles
